Battery-box-container composition and method of making same



Patented Apr. 22, 1930 UNITED STATES PATENT OFFICE RUFUS N. CHAMBERLAIN, or DEPEW, NEW YORK, ASSIGNOR T0 GOULD STORAGE BATTERY COMPANY, INC., OF NEW YORI K, N. Y., A CORPORATION OF NEW YORK BATTERY-BOX-CONTAINER COMPOSITION AND METHOD OF MAKING- SAME No Drawing.

This invention relates to a composition of matter Which is primarily intended for use in the manufacture of containers or boxes for storage batteries.

To this end, the primary object of my invention, generally considered, is to provide a compositlon of matter which may be readily and inexpensively produced and which is adapted, b the process hereinafter to'be described, tolie formed into a box or container for storage batteries and the like.

Prior to my invention, containers for storage batteries have generally been made of wood which is not acid-proof or of rubber which is expensive and brittle in extreme cold, or of a mixture of asphaltum and some vegetable fiber, or of porcelain or clay which is not only diflicult to manufacture in the desired density but is brittle and is moreover diflicult to produce in uniform sizes by reason of the Warpage and distortion in the burning process.

In carrying out my invention I preferably employ a composition of matter which is adapted to make a one-piece or unit con-- tainer sometimes called a monobloc which is preferably adapted to have one or more partitions molded or formed in it to make the necessary number of cell compartments for use with a 4, 6 or 12 volt battery, as desired. 4

As mentioned above, acid resisting composition containers have heretofore been made generally of Trinidad or Bermudez asphalt which contains a large percentage of earthy matter and is not uniform or stable as the almost one hundred percent bituminous material, which is obtained from petroleum asphalt or gilsonite. Each of these materials shows, on analysis, between ninetyei ht and ninety-nine percent of bitumen.

11 carrying out my invention I employ a composition of matter which has the follow- 5.11% characteristics irst, acid resisting qualities; second, structural strength; third, proper hardness and firmness after forming; and, fourth, a wide temperature range. I obtain these qualities by preferably employing such ingredients as are not affected by the ,battery acids, such,

Application filed September 25, 1925. Serial No. 58,555.

ness or hardness and a wide temperature range are obtained by the use of the inert mineral filler which is employed.

I have found in the actual practice of my invention that a mixture composed of bituminous and asphalt materials of low melting points, approximately 275 F. will have its melting point raised by the addition thereto and the commingling therewith of the fibrous material and the inert filler, all of which are obtained in suitable proportions, as will be hereinafter pointed out, and by using this composition of matter I produce a battery box or container which is acid-proof and is not appreciably affected by extremes of temperature either by softening at high temperatures or by becoming brittle at low temperatures.

I preferably employ a mixture consisting of substantially 33% petroleum asphalt; 17% select gilsonite, 28% volcanic pumice stone, and 22% acid-proof asbestos. It will be, of course, understood that the proportions stated herein may be Varied through a wide range under varying conditions without affecting the invention and it is also to be understood that I may substitute for the pumice mentioned silica in its pure state, or I may substitute for both the pumice stone and acid-proof asbestos, silica fibre which is now bein manufactured in commercial quailt-ities. T e asphalt and gilsonite constituting the bituminous materials I have found by experiment, may vary in proportions from 40% to of the total mass, while the inert filler of the composition may range from 20% to a serviceable and durable case or container having all of the desired and necessary prop erties.

When using asbestos as the fibrous bmder of the composition, it is preferable to employ an asbestos fibre of the am hibole group. An especially satisfactory as estos fibre 1s that known to mineralogists as crocidolite, and distributed under the trade name blue asbestos or blue African asbestos. Such asbestos fibre resists attack by acid of storage battery strength, and thus permits the production of a composition of matter for batter box use which is wholly acid-proof.

prefer, inthe production of battery cases,

" to put the proper percentage of petroleum asphalt, gilsonite, inert filler and fibrous material in a large mixer which is heated by any suitable means and after the asphalt and gilsonite have melted and are thoroughly mixed with the fibrous material and inert filler and form a plastic or semi-fluid composition, to take from this composition the necessary amount and place the same in a mold and subject the same to pressure, either hydraulic or otherwise, so as to form a battery container conforming to the configuration of the mold. The pressed material is then allowed to cool sufiiciently to .become rigid and then removed from the mold and allowed to cool to atmospheric temperature.

I have found that the preferable temperature range at which the composition of matter ma be most easily handled and manipulated hes between 350 F. and450 F., and the higher the temperature of the materlal or composition the less pressure is required to form the container.

A composition of matter produced in accordance with the invention is characterized by such homogeneity, hardness, toughness and stability as to render it suitable for battery boxes and thelike. In the composition, the petroleum asphalt and gilsonite mutually act to form an homogeneous mass of substantially higher melting point than the petroleum asphalt and substantially less brittle than the gilsonite. The fibrous binder imparts the requisite toughness and the inert filler augments the homogeneity and hardness of the mass to impart the stability requisite for battery box use. Battery boxes moldedv or otherwise made from the improved composition have the external appearance of hard rubber containers, but are stronger and much more durable; and are resistant both to physical shocks and to attack by storage battery acid. Nevertheless, such battery boxes are much less expensive to produce than the hard. rubber containers.

Having thus described myinvention, what I claim is:

1. A battery box comprisin etroleum asphalt, gilsonite, an acidroo fibrous binder and an inert acid-proof ller, the bituminous elements comprising substantially 50% of the composition.

2. A composition of matter characterized physically by such homogeneity, hardness, toughness and stability as to render 1t suitable for battery boxes and the like, said composition of matter being made of petroleum asphalt, gilsonite, a fibrous binder and an inert filler, the constituent materials of said composition being blended in relative proportions such that the petroleum asphalt and ilsonite mutually act in the composition to orm an homogeneous mass of substantially higher meltin point than the petroleum asphalt and less rittle than gilsonite, and such that the fibrous binder imparts the requisite toughness and the inert filler augments the homogeneity and hardness of the mass to impart the requisite stability to the composition.

3. A storage battery box molded of a composition comprising petroleum asphalt, gilsonite, a fibrous binder and an inert filler, the said constituent materials thereof being united to form a blend including such relative proportions of said materials as to produce a hard yet tough, homogeneous, substantially non-cellular mass which is resistant both to physical shocks and to attack by storage battery acid.

I 4. A composition of matter characterized physically by such homogeneity, hardness, toughness and stability, as to render it suitable for battery boxes and the like, said composition of matter being made of petroleum asphalt, gilsonite, acid-proof asbestos fibre and an inert filler, the said constituent materials thereof being united to form a blend including such relative proportions of said materials as to produce a hard yet tough, homogeneous mass which is resistant both to physical shocks and to attack by storage battery acid.

5. A composition of matter characterized. physically by such homogeneity, hardness, toughness and stability as to render it suitable for battery boxes and the like, said composition of matter being made of substantially 33% petroleum asphalt, substantially 17% gilsonite, substantially 22% acid-proof asestos fibre and substantially 28% volcanic pumice stone, the said constituent materials being blended to produce a hard yet tough,

homogeneous mass which is resistant both to physical shocks and to attack by storage battery acid.

6. A battery box molded ofa composition comprising substantially 33% petroleum asphalt, 17% gilsonite, 22%acid-proof asbestos fibre and 28% volcanic pumice, the said constituent materials being blended into a hard yet tough, homogeneous mass which is resistant both to physical shocks and to attack by storage battery acid.

7. A battery box made of a composition of matter comprisin petroleum asphalt, gilson rous material and an inert ite, a binder of fi filler, the said constituent materials being blended into a hard yet tough, homogeneous,

substantially non-cellular mass which is resistant both to physical shocks and to attack by storage battery acid and in which the gilsonite and petroleum asphalt range from 40% ranging from 60% to 40% ofthe total composition, said materials being blended to form a hard yet tough, homogeneous mass which is resistant both to physical shocks and to attack by storage battery acid.

In testimony whereof I aflix my signature.

RUFUS N. CHAMBERLAIN. 

